Note: Descriptions are shown in the official language in which they were submitted.
.,
CA 02360939 2001-07-24
1
DESCRIPTION
POLYMER ELECTROLYTE FUEL CELL AND METHOD FOR ITS
PRODUCTION
TECHNICAL FIELD
The present invention relates to a polymer
electrolyte fuel cell employing specific current
collectors and a method for its production.
BACKGROUND ART
Attention has been drawn to a hydrogen oxygen fuel
cell as a power generation system which gives no
substantial adverse effect to the global environment,
since the reaction product is only water in principle.
With a polymer electrolyte fuel cell which is being
studied recently, a very high output is expected at a low
operation temperature of from room temperature to about
150°C. In such a case, it is assumed to use, as a fuel,
hydrogen gas containing e.g. carbon dioxide, obtained by
reforming e.g. methane, methanol or gasoline.
On the other hand, a polymer electrolyte fuel cell
has a low operation temperature. Accordingly, exhaust
heat can hardly be utilized, for example, as an auxiliary
power, and it is utilized only for hot water at best. To
offset such a drawback, it is necessary for the polymer
electrolyte fuel cell to secure a high output density.
Further, for practical application, it is required to
secure performance of a high energy efficiency and a high
output density even under an operation condition where
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the fuel and air utilization ratios are high.
As the electrolyte for the polymer electrolyte fuel
cell, a perfluorocarbon sulfonic acid type cation
exchange membrane, which is an ultrastrong acid, is
mainly used, in view of the chemical stability and
electric conductivity. When such an acid electrolyte is
used, the following reaction occurs at an air electrode,
whereby water will be formed.
1/202 + 2H+ + 2e- -~ H20
Therefore, when the polymer electrolyte fuel cell is
operated under such conditions as a low operation
temperature, a high current density and a high gas
utilization ratio, clogging (flooding) of the electrode
is likely to take place due to condensation of steam, at
the air electrode where water is formed. Further, gases
to be supplied to the fuel electrode and the air
electrode, are usually wetted not to dry the ion exchange
membrane in order to maintain the electric conductivity
of the ion exchange membrane which is the polymer
electrolyte. Accordingly, also by such wetted gases,
flooding of the electrode is likely to take place.
Accordingly, in order to obtain a stable performance
of the fuel cell for a long period of time, it is
necessary to impart water repellency to the catalyst
layers and the current collectors to supply gases to the
catalyst layers, so as to prevent such flooding.
Particularly in the case of a polymer electrolyte fuel
CA 02360939 2001-07-24
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cell whereby a high output density at a low temperature
is desired, it is important to secure sufficient gas
supply to the catalyst layers by imparting water
repellency to the current collectors.
For example, as a method for imparting water
repellency to a current collector made of e.g. carbon
paper or carbon cloth, a method of incorporating a
fluorine-containing polymer to a current collector, has
heretofore been known. The fluorine-containing polymer
may, for example, be polytetrafluoroethylene (hereinafter
referred to as PTFE), a
tetrafluoroethylene/hexafluoropropylene copolymer or a
tetrafluoroethylene/perfluoro(alkyl vinyl ether)
copolymer. Each of them is a resin not soluble in a
solvent. In this specification, an A/B copolymer
represents a copolymer comprising polymer units based on
A and polymer units based on B.
In order to incorporate such a fluorine-containing
polymer as a water repellent material to a current
collector, a method may, for example, be employed in
which a sheet constituting a current collector is
impregnated in a dispersion of a powder of a fluorine-
containing polymer, followed by baking at a temperature
of about 300°C. Usually, a surfactant is used as a
dispersing agent for such a dispersion of a fluorine-
containing polymer, and the surfactant is removed by
baking. The surfactant is a hydrophilic substance, and
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therefore, if it is not sufficiently removed, no adequate
water repellent effect by the fluorine-containing polymer
can be obtained.
In the above method, high temperature baking is
required, whereby there will be many restrictions in the
design of the electrodes. For example, a catalyst layer
usually contains an ion exchange resin for coating the
catalyst, and the heat resistant temperature of such an
ion exchange resin is about 200°C. Therefore, the above-
mentioned baking treatment can not be applied in a state
where a catalyst layer is laminated on the current
collector, and the current collector will have to be
baked alone.
Further, the particle size of the above-mentioned
solvent-insoluble fluorine-containing polymer is at least
0.1 um as a primary particle size, and when it is used as
a powder, it is usually granulated, whereby the average
secondary particle size is usually at a level of from a
few ~zm to 500 pm. Accordingly, when such a solvent-
insoluble fluorine-containing polymer is incorporated to
a current collector, if the amount is small, it can not
be continuously present, and the current collector will
have water repellency only locally.
Therefore, portions of the current collector where
no fluorine-containing polymer is present, will gradually
be wetted as the fuel cell is used, and wetted regions
will spread therefrom, thus leading to a substantial
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decrease in the water repellency of the entire current
collector. Consequently, pores of the current collector
will be clogged by water, and there will be a problem
that the supply of a gas to the catalyst layer is
5 hindered, and the concentration overpotential increases
to substantially lower the output voltage. Further, the
above-mentioned fluorine-containing polymer is
substantially spherical in its shape, and even when
subjected to baking treatment, the bonding strength to
the sheet which constitutes the current collector, is
weak, whereby there will be also a problem that the
fluorine-containing polymer is likely to partially fall
off when used for a long period of time.
Therefore, in order to impart adequate water
repellency continuously over the entire current
collector, a large amount of the fluorine-containing
polymer will be required. However, the above-mentioned
solvent-insoluble fluorine-containing polymer is
electrically insulating, and if it is incorporated in a
large amount in the current collector, the resistance of
the current collector increases. Further, there is a
problem that the fluorine-containing polymer particles
themselves are likely to clog the pores of the current
collector.
Therefore, it is an object of the present invention
to provide a current collector for a polymer electrolyte
fuel cell, which has high water repellency as compared
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with the prior art and which is capable of maintaining
adequate water repellency for a long period of time,
thereby to provide a polymer electrolyte fuel cell which
has a high output density and which provides a stabilized
performance for a long period of time.
DISCLOSURE OF THE INVENTION
The present invention provides a polymer electrolyte
fuel cell comprising a polymer electrolyte made of an ion
exchange membrane, catalyst layers disposed on both sides
thereof, and current collectors disposed on the outer
sides of the catalyst layers, wherein the current
collectors are made of a porous sheet having a solvent-
soluble fluorine-containing polymer having substantially
no ion exchange groups, deposited on its surface.
Further, the present invention provides a method for
producing a polymer electrolyte fuel cell, which
comprises disposing catalyst layers on both sides of a
polymer electrolyte made of an ion exchange membrane, and
further disposing current collectors made of a porous
sheet on the outer sides of the catalyst layers, wherein
the current collectors are obtained by impregnating or
spraying a solution having a solvent-soluble fluorine-
containing polymer having substantially no ion exchange
groups, dissolved in a solvent, to the porous sheet, to
deposit the fluorine-containing polymer on the porous
sheet.
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BEST MODE FOR CARRYING OUT THE INVENTION
The current collectors in the present invention
contain a solvent-soluble fluorine-containing polymer
having substantially no ion exchange groups, so that they
have water repellency. In this specification, the
solvent-soluble fluorine-containing polymer is a
fluorine-containing polymer such that a solvent capable
of dissolving the fluorine-containing polymer, exists,
and the solvent is not particularly limited. However, it
is preferably a fluorine-containing polymer which does
not substantially dissolve in a solvent such as water or
an alcohol which will be a reactant or a product in the
electrode reaction of the fuel cell.
The solvent-soluble fluorine-containing polymer in
the present invention may be one partially fluorinated or
one wherein all hydrogen atoms are fluorinated. However,
it is preferably in a solid state within the temperature
range for use of a polymer electrolyte fuel cell.
Specifically, it is preferably in a solid state within a
range of from room temperature to 150°C.
Further, the solvent-soluble fluorine-containing
polymer in the present invention has substantially no ion
exchange groups. Here, the ion exchange groups are
specifically sulfonic acid groups, carboxylic acid
groups, etc. Here, "have substantially no ion exchange
groups" means that the ion exchange groups contained in
the solvent-soluble fluorine-containing polymer are at
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most 0.1 meq./g dry resin, particularly preferably at
most 0.05 meq./g dry resin.
As such a solvent-soluble fluorine-containing
polymer, a polymer having a fluorine-containing aliphatic
ring structure in its molecule, is preferred. The
polymer having a fluorine-containing aliphatic ring
structure in its molecule, is hardly crystallizable due
to twisting of the molecule attributable to its molecular
structure and is soluble in a fluorine type solvent. The
polymer having a fluorine-containing aliphatic ring
structure in its molecule, may, for example, be a polymer
containing polymer units represented by the following
formula 1, 2, 3 or 4. Specifically, a fluorine-
containing polymer containing polymer units represented
by any one of the following formulae 5 to 11, is
preferred. Further, a fluorine-containing polymer
containing polymer units represented by the formula 12 or
13, is also preferred.
In the formula 1, R1 is a fluorine atom or a
trifluoromethyl group, p is an integer of from 0 to 5, q
is an integer of from 0 to 4, r is 0 or 1, and p+q+r is
from 1 to 6; in the formula 2, each of s, t and a which
are independent of one another, is an integer of from 0
to 5, and s+t+u is from 1 to 6; in the formula 3, each of
R2 and R3 which are independent of each other, is a
fluorine atom or a trifluoromethyl group; and in the
formula 4, v is 1 or 2.
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CFZ'
--~CFZ ~ CF~-
(C'2) p ~ F R 1) r
0 ( C F 2 ) q ~ ~ ~ Formula 1
CF2~
-~ C F 2 ~ C F -j--
(CFa)s (CFa)u
/ ~ ~ ~ Formula 2
(CFC 1)t
-f-CF CF ~
O 0
C ~ ~ ~ ~ Formula 3
~R s
~CFZ-CF CF-CFZ-~-
~ ~ Formula 4
0-(CF2)~
CF\ CFZ'
--~CF2-~ CFA- ~CFZ-~ CF-)-
~Fa
0 -CFZ
~ ~ ~ Formula 5 C F 2
~ ~ ~ Formula 6
CF\ /CF~
--~CFZ-~ CF-'J-- _"~CFz-CF CF~-
CFZ CFZ
0 CF ~ /
~CF3 CFC 1
~ ~ Formula 7 ~ ~ ~ Formula 8
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CFz -~'CF-CF -~-
-'f'CFZ-CF CF-j--
CFZ ~ F
2
\CFZ/ CF3 cF3
5
~ ~ ~ Formula 9 ~ ~ ~ Formula 10
-f CFz-CF-CF-CFz~-- -f CFZ-CF-CF-CF2~
F
~C~ ~C~
10 a a
~ ~ ~ Formula 11 ~ ~ ~ Formula 12
F2
CF ~ \CF-~-
CFz
~ ~ ~ Formula 13
As the solvent-soluble fluorine-containing polymer
in the present invention, a homopolymer of polymer units
represented by any one of the formulae 5 to 13 is
preferred, but a copolymer containing at least two types
of these polymer units, is also preferred. Further, it
may be a copolymer containing polymer units based on a
monomer having no fluorine-containing ring structure,
such as tetrafluoroethylene or hexafluoropropylene.
The solvent which is capable of dissolving such a
fluorine-containing polymer, is mainly a fluorine-
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containing solvent. For example, perfluorobenzene,
dichloropentafluoropropane, Afluide (tradename, for a
fluorine-containing solvent, manufactured by Asahi Glass
Company, Limited) or perfluoro(2-butyltetrahydrofuran)
may be mentioned. The concentration of the solution
having the fluorine-containing polymer dissolved, may be
from 0.01 to 50~, based on the total mass of the
solution.
Further, the molecular weight of the solvent-soluble
fluorine-containing polymer in the present invention is
preferably from about 2,000 to 200,000, particularly from
about 5,000 to 10,000. With a solution of the fluorine-
containing polymer, if the mass concentration is equal, a
solution having one having a large molecular weight
dissolved usually has a high viscosity. When a solvent-
soluble fluorine-containing polymer having a molecular
weight within the above-mentioned range, is used, if the
concentration of the solution having such a polymer
dissolved in a solvent, is adjusted, it is possible to
bring the viscosity to a level excellent in the
penetrability into the porous sheet constituting a
current collector. Accordingly, a water repellency can
be imparted easily to the above sheet by impregnating the
sheet in this solution or by spraying this solution to
the sheet. Further, the solution of the solvent-soluble
fluorine-containing polymer having a molecular weight
within the above range, has a film-forming property, and
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a coating film obtainable by drying the solution, is
excellent also in the durability.
In the present invention, in order to increase the
physical adhesive strength of the solvent-soluble
fluorine-containing polymer to the porous sheet
constituting the current collectors, it is preferred that
the fluorine-containing polymer solution is incorporated
to the sheet by a method such as spraying or
impregnation, followed by baking at a temperature of from
about 100 to 250°C, more preferably from 150 to 200°C.
The baking atmosphere at that time is not particularly
limited, but is preferably in vacuum or in an inert gas
atmosphere. The fluorine-containing polymer solution
does not contain e.g. a surfactant to be removed, whereby
the adhesive strength to the sheet can be improved at a
temperature lower than the decomposition temperature of
the ion exchange resin. Accordingly, baking may be
carried out after integrating the current collectors with
the catalyst layers. Further, the solvent-soluble
fluorine-containing polymer is preferably such that
hydrogen atoms are all fluorinated, whereby it is
excellent in the chemical resistance and stable even in
an oxidizing or reducing atmosphere.
In the present invention, the solvent-soluble
fluorine-containing polymer is incorporated to the
current collectors, and it is further preferred that the
solvent-soluble fluorine-containing polymer is
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incorporated also in the catalyst layers. If the
solvent-soluble fluorine-containing polymer is
incorporated to the catalyst layers, the water repellency
will further be improved, whereby flooding can be more
effectively be suppressed. Accordingly, a higher output
can be maintained even if the fuel cell is used for a
long period of time. Here, the solvent-soluble fluorine-
containing polymer to be incorporated to the catalyst
layers may be the same or different from the solvent-
soluble fluorine-containing polymer incorporated to the
current collectors, but it is preferably a solvent-
soluble fluorine-containing polymer exemplified above
with respect to the current collectors.
In the present invention, the porous sheet
constituting the current collectors is preferably made of
a carbonaceous material, and carbon paper or carbon cloth
(one having carbon fibers formed into a cloth) is, for
example, preferred. Of such a porous sheet, the
thickness is preferably from 0.1 to 1 mm, and the
porosity is preferably from 30 to 90~, particularly
preferably from 70 to 80~. If the current collectors are
too thick, the dispersibility of the gas deteriorates,
and the output of the fuel cell is likely to deteriorate.
Further, if the porosity is too low, the gas will not be
efficiently supplied to the catalyst layers. Further, if
the thickness of the current collectors is too thin or
the porosity is too high, the strength of the current
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collectors tends to be low.
In the polymer electrolyte fuel cell of the present
invention, the catalyst layers are disposed on both sides
of the polymer electrolyte made of an ion exchange
membrane, and the current collectors are disposed on the
outer sides thereof. The current collectors may be
disposed as directly in contact with the catalyst layers
or may be disposed as in contact via a gas diffusion
layer.
As such a gas diffusion layer, a water repellent
sheet made of fine particles of carbon and PTFE may, for
example, be used. To the gas diffusion layer, water
repellency may be imparted together with the current
collector. When a gas diffusion layer is present between
the current collector and the catalyst layer, the gas can
be supplied more uniformly to the catalyst layer.
Further, when the current collectors are made of e.g.
carbon paper, the catalyst layers or ion exchange
membranes are likely to be damaged by e.g. fluffing, but
by the presence of the gas diffusion layer, such damage
can be prevented.
As a method for incorporating the solvent-soluble
fluorine-containing polymer to the current collectors, a
method may, for example, be mentioned wherein a porous
sheet to constitute a current collector, is impregnated
in a solution having the fluorine-containing polymer
dissolved, followed by removing the solvent. Otherwise,
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in the process for the production of the above porous
sheet, its constituting material may be impregnated in
the fluorine-containing polymer solution. Otherwise, the
above porous sheet may be put together with a catalyst
5 layer and impregnated together in a fluorine-containing
polymer solution. The solution of the solvent-soluble
fluorine-containing polymer is not required to use a
surfactant, and simply by heating at a temperature where
the solvent can be removed, the fluorine-containing
10 polymer can be deposited on the current collectors to
impart water repellency.
Further, the solvent which is capable of dissolving
the solvent-soluble fluorine-containing polymer, is
usually a fluorine-containing carbon type solvent, and in
15 many cases one having a low boiling point of not higher
than 60°C. Accordingly, a solvent having such a low
boiling point can be removed simply by leaving the porous
sheet containing the fluorine-containing polymer solution
to stand at room temperature, whereby the porous sheet
can be made water repellent very simply.
Further, the fluorine-containing polymer can be
incorporated into the current collectors in the form of a
solution, whereby by adjusting the viscosity of the
solution, the fluorine-containing polymer can be
distributed uniformly even into the interior of the pores
of the porous sheet constituting the current collector.
Accordingly, by means of the solvent-soluble fluorine-
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containing polymer, the porous sheet surface can be
covered efficiently with a small amount as compared with
a fluorine-containing polymer which is insoluble in a
solvent. Further, even when the water repellency of the
current collectors has deteriorated by the use of the
fuel cell for a long period of time, the water repellency
can be imparted again to the current collectors by an
operation such as a spraying of the fluorine-containing
polymer solution, as the case requires.
In the present invention, a solution having the
fluorine-containing polymer dissolved, is used, whereby
the fluorine-containing polymer present after the removal
of the solvent upon drying, can cover the surface of the
sheet, irrespective of the type of the porous sheet
constituting the current collectors, such as woven fabric
or non-woven fabric, and irrespective of the sizes of
pores of the sheet. Accordingly, it is possible to
impart high water repellency to any sheet having a porous
structure.
Further, the solvent-soluble fluorine-containing
polymer in the present invention is incorporated to the
current collectors preferably in an amount of from 0.001
to 60~, particularly preferably from 0.01 to 10~, based
on the total mass of the current collectors. Within this
range, the current collectors will have excellent water
repellency over a long period of time.
Further, when the porous sheet to constitute the
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current collectors, is treated for water reppelency, the
viscosity of the fluorine-containing polymer solution may
be adjusted by a diluting solvent. As such a diluting
solvent, a fluoroalkane, a fluorotrialkylamine, a
fluoroalkyltetrahydrofuran, a ketone, an ester, a
chloroethane, a benzene derivative, an alcohol such as
methanol, ethanol or isopropyl alcohol, a fluorocarbon, a
hydrofluorocarbon or a hydrochlorofluorocarbon, may, for
example, be mentioned.
The current collectors in the present invention are
excellent not only in the initial water repellency, but
the water repellency can be maintained even when it is
used for a long period of time, whereby the output of the
fuel cell can be maintained at a high output level
constantly for a long period of time. Further, the water
repellency can be imparted more efficiently than ever,
whereby the amount of the fluorine-containing polymer as
an insulating resin contained in the current collectors,
can be reduced. Accordingly, the electric resistance of
the current collectors can be reduced, and the porosity
of the current collectors can be increased. Thus, the
current collectors in the present invention are excellent
in the gas diffusion property, and have a low
resistanece, and they are useful for both an air
electrode and a fuel electrode.
In the present invention, the above current
collectors can be used for either air electrodes or fuel
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electrodes, or they may be used for both electrodes.
However, at the air electrodes, water will form by the
reaction, and flooding is likely to occur, and
accordingly, at least for the air electrodes, it is
preferred to use them. Even when the above current
collectors are used only for the air electrodes, and
current collectors having water repellency treatment
applied by a conventional solvent-insoluble fluorine-
containing polymer, are used for the fuel electrodes, it
is possible to provide a fuel cell having a long term
reliability. Further, even when the solvent-insoluble
fluorine-containing polymer and the solvent-soluble
fluorine-containing polymer according to the present
invention, are used in combination and incorporated
together in the current collectors, it is possible to
obtain current collectors having high water repellency
for a long period of time.
Now, the present invention will be described in
detail with reference to Examples (Examples 1 to 4) and
Comparative Examples (Examples 5 and 6), but the present
invention is by no means restricted thereto.
EXAMPLE 1
A polymer (hereinafter referred to as the polymer P)
comprising polymer units represented by the formula 11
and having a molecular weight of about 100,000, was
dissolved in a solvent mixture of perfluoro(2-
butyltetrahydrofuran) and perfluoro(tributylamine) in a
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mass ratio of 1:1, so that the concentration of the
solute would be 2~ of the total mass. In this solution,
carbon paper (TGP-H-060, tradename, manufactured by Toray
Industries Inc.) was impregnated, whereby the above
polymer was deposited so that it would be present in an
amount of 0.6 mg/cm2 per unit area of the carbon paper.
This carbon paper was dried at room temperature (25°C) to
remove the solvent, thereby to obtain a current
collector.
A catalyst having platinum supported on a carbon
black powder in an amount of 40~ of the total mass, and a
solution having an ion exchange resin made of a
CF2=CFz/CFZ=CF-OCFZCF (CF3 ) -OCFZCFZS03H copolymer having an
ion exchange capacity of 1.1 meq./g dry resin dispersed
in a solvent mixture of ethanol and 1,3-dichloro-
1,1,2,2,3-pentafluoropropane in a mass ratio of 1:1, were
mixed to obtain a dispersion A. In this dispersion A,
the mass ratio of the catalyst to the ion exchange resin
was 0.75:0.25.
Then, a solution having a catalyst dispersed was
prepared in the same manner as for the dispersion A
except that as the ion exchange resin, one having an ion
exchange capacity of 0.91 meq./g dry resin, was used, and
this liquid was designated as a dispersion B.
As an electrolyte membrane, an ion exchange membrane
of a perfluorosulfonic acid type (Flemion R, tradename,
manufactured by Asahi Glass Company, Limited, ion
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exchange capacity: 1.0 meq./g dry resin, dried film
thickness: 50 um) was used. To this ion exchange
membrane, the dispersion A was sprayed to the hydrogen
electrode side, and the dispersion B was sprayed to the
5 air electrode side, so that the platinum content would,
respectively, be 0.5 mg/cm2, to form catalyst layers,
thereby to obtain a membrane electrode assembly having
catalyst layers formed on both sides of the ion exchange
membrane. This assembly was sandwiched between a pair of
10 the above current collectors and assembled in a cell to
obtain a single cell.
Using this single cell, a continuous operation was
carried out at a constant current of 1.0 A/cm2 at a cell
temperature of 80°C under a normal pressure (0.1 MPa)
15 with a supplied gas being hydrogen/air at a gas
utilization ratios of 70~ of hydrogen and 40~ of air.
The output voltages upon expiration of 10 hours, 500
hours and 1000 hours after the initiation of the
operation, were measured. The results are shown in Table
20 1.
EXAMPLE 2
The current collectors obtained in Example 1 were
baked in vacuum at 150°C for one hour. A single cell was
obtained in the same manner as in Example 1 except that
the baking treated current collectors were employed.
Using this single cell, the operation was carried out in
the same manner as in Example 1, and the output voltages
CA 02360939 2001-07-24
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were measured in the same manner as in Example 1. The
results are shown in Table 1.
EXAMPLE 3
The polymer P was dissolved in a solvent mixture of
perfluoro(2-butyltetrahydrofuran) and
perfluoro(tributylamine) in a mass ratio of 1:1, so that
the concentration of the solute would be 0.5~ of the
total mass. In this solution, carbon paper (TGP-H-060,
tradename, manufactured by Toray Industries Inc.) was
impregnated, whereby the above polymer was deposited so
that it was present in an amount of 0.3 mg/cm2 per unit
area of the carbon paper. This carbon paper was baked at
150°C for one hour, to obtain a current collector.
A single cell was prepared in the same manner as in
Example 1 except that this current collector was
employed, and using this single cell, the operation was
carried out in the same manner as in Example 1, and the
output voltages were measured in the same manner as in
Example 1. The results are shown in Table 1.
EXAMPLE 4
The polymer P was dissolved in the dispersion B, and
this was designated as a dispersion C. The mass ratio of
the catalyst, the ion exchange resin and the polymer P in
this dispersion C was 0.72:0.24:0.04. A membrane
electrode assembly was prepared in the same manner as in
Example 1 except that on the air electrode side, the
dispersion C was used instead of the dispersion B.
CA 02360939 2001-07-24
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A single cell was prepared in the same manner as in
Example 1 by using the current collectors obtained in
Example 2 as the current collectors and using the above
membrane electrode assembly. By using this single cell,
the operation was carried out in the same manner as in
Example 1, and the output voltages were measured in the
same manner as in Example 1. The results are shown in
Table 1.
EXAMPLE 5
A current collector was obtained in the same manner
as in Example 1 except that the solution in which the
carbon paper was impregnated, was a diluted solution of a
solvent-insoluble PTFE dispersion (AD-1, tradename,
manufactured by Asahi ICI Fluoropolymers Co., Ltd.) and
baking was carried out in nitrogen atmosphere at 350°C.
Further, the amount of PTFE deposited per unit area of
the current collector was 0.6 mg/cmz. A single cell was
obtained in the same manner as in Example 1 except that
this current collector was used. Using this single cell,
the operation was carried out in the same manner as in
Example 1, and the output voltages were measured in the
same manner as in Example 1. The results are shown in
Table 1.
EXAMPLE 6
A single cell was obtained in the same manner as in
Example 1 by using the membrane electrode assembly
obtained in Example 4 and the current collector obtained
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in Example 5. Using this single cell, the operation was
carried out in the same manner as in Example 1, and the
output voltages were measured in the same manner as in
Example 1. The results are shown in Table 1.
Table 1
Output voltage
of the single
cell (V)
After 10 hours After 500 hours After 1000 hours
Example 0.59 0.57 0.55
1
Example 0.59 0.58 0.57
2
Example 0.58 0.56 0.55
3
Example 0.61 0.61 0.60
4
Example 0.58 0.54 0.49
5
Example 0.59 0.56 0.53
6
INDUSTRIAL APPLICABILITY
In the present invention, a solvent-soluble
fluorine-containing polymer is used, whereby by its
solution, a porous sheet to constitute a current
collector can be treated for water repellency.
Accordingly, the surface of the porous sheet can be
covered by the fluorine-containing polymer efficiently
with a small amount irrespective of the shape or the pore
structure of the porous sheet. Further, by simply
removing the solvent from the porous sheet having the
fluorine-containing polymer solution incorporated,
excellent water repellency can be uniformly imparted for
a long period of time. Further, heating at a high
CA 02360939 2001-07-24
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temperature is not required for the process for imparting
water repellency by incorporating the solvent-soluble
fluorine-containing polymer to the current collector, the
degree of freedom in designing the gas diffusion
electrode containing the current collector, is high.
In the present invention, current collectors having
low resistance and high water repellency for a long
period of time, thus obtainable, are used, whereby it is
possible to provide a polymer electrolyte fuel cell which
provides a high output density and which undergoes little
deterioration with time of the output characteristics.
